Valve Lash Adjustment Guide

Testing and Adjusting Ridho Bagus Fitriyanto | AB – 1K
Testing and Adjusting

3114, 3116 and 3126 Industrial, Marine and Generator Set Engines
Media Number -SENR9558-04 Publication Date -01/10/2008 Date Updated -29/10/2008

i01582980
Engine Valve Lash - Inspect/Adjust

SMCS - 1102-025
/ sisweb/ siswe b/ m / sisweb/ mediasea
To prevent possible injury, do not use the starter to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve clearance.
Note: Valve lash is measured between the rocker arm and the valve. All measurements and
adjustments must be made with the engine stopped and the valves FULLY CLOSED.
Valve Lash Check

An adjustment is NOT NECESSARY if the measurement of the valve lash is in the acceptable
range in Table 1.
Table 1
Valve Lash Check (Stopped Engine)
Inlet
0.30 to 0.46 mm (0.012 to 0.018 inch)
Exhaust
0.56 to 0.72 mm (0.022 to 0.028 inch)
If the measurement is not within this range, an adjustment is necessary. Refer to "Valve Lash
Adjustment" for the proper procedure.
Valve Lash Adjustment

Table 2
Valve Lash Setting (Stopped Engine)
Inlet
0.38 mm (0.015 inch)
Exhaust
0.64 mm (0.025 inch)
View Image
Illustration 1 g00689649
Cylinder and valve location
(A) Exhaust valves
(B) Inlet valves

View Image
Cylinder and valve location
(A) Exhaust valves
(B) Inlet valves
Use the following procedure to adjust the valve lash:
View Image
Valve Adjustment (Typical Example)
(1) Valve
(2) Rocker arm
(3) Adjustment locknut
(4) Adjustment screw
1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing
and Adjusting, "Finding Top Center Position for No. 1 Piston".
2. With the No. 1 piston at the top center position of the compression stroke, an adjustment
can be made to the valves. Refer to Testing and Adjusting, "Gear Group (Front) - Time"
for the information that is required in order to adjust the valves.
Note: Before any actual adjustment is made, lightly tap the rocker arm at the top of the
adjustment screw with a soft mallet. This will ensure that the lifter roller seats against the
camshaft's base circle.
3. Loosen adjustment locknut (3) .
4. If there is not enough clearance in order to insert the feeler gauge between rocker arm (2)
and valve (1), turn adjustment screw (4) counterclockwise in order to increase the
clearance.
5. Place the appropriate feeler gauge between rocker arm (2) and the valve (1). Then, turn
the adjustment screw in a clockwise direction. Slide the feeler gauge between the rocker
arm and the valve. Continue turning the adjustment screw until a slight drag is felt on the
feeler gauge. Remove the feeler gauge.
6. Tighten adjustment locknut (3) to a torque of 25 ± 7 N·m (18± 5 lb ft). Do not allow the
adjustment screw to turn while you are tightening the adjustment locknut. Recheck the
valve lash after tightening the adjustment locknut.
7. Remove the timing bolt and turn the flywheel by 360 degrees in the direction of engine
rotation. This will put the No. 6 piston at the top center position on the compression
stroke. Install the timing bolt in the flywheel.
8. Adjust the valve lash on the remaining valves. Refer to Testing and Adjusting, "Gear
Group (Front) - Time" for the information that is required in order to adjust the valves.
9. Repeat Step 3 through Step 6 for these valve adjustments.
10. Remove the timing bolt from the flywheel after all adjustments to the valve lash have
been made. Reinstall the timing cover.
Refer to Testing and Adjusting, "Unit Injector - Adjust".
Using the 223-2454 Tool Group on 3114,

3116, and 3126 Engines with Mechanical
Unit Injectors (MUI){0374, 0599, 0701,

0706, 1251, 1252, 1254} Caterpillar
Using the 223-2454 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit
Injectors (MUI){0374, 0599, 0701, 0706, 1251, 1252, 1254}
Usage:
120H 124
Engine: Commercial with Mechanical Unit Injection 3126

Engine: Machine with Mechanical Unit Injection 3126
Engine: Truck with Mechanical Unit Injection 3116
Engine:Truck with Mechanical Unit Injection 3114 3116 3126
Engine:Commercial with Mechanical Unit Injection 3114 3116
Engine:Machine with Mechanical Unit Injection 3114 3116
Engine:Machine 3114 3126
Engine:Truck with Hydraulic Electronic Unit Injection (HEUI) 3116 3126
Engine:Truck with Mechanical Unit Injection 3114
Generator Set: 3114 3116
Industrial Engine: 3114 3116 3126
Machine Engines: 3114 3116 3126
Marine Engine: 3116 3126
Introduction
European Union Compliant, CE Marked
Important Safety Information

Think Safety
Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must be alert to potential
hazards. This person should also have the necessary training, skills, and tools to perform these
functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous

and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until
you have read and understood the operation, lubrication, maintenance, and repair
information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
"DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown
below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE"
labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are therefore, not all inclusive.
If a tool, procedure, work method, or operating technique that is not recommended by
Caterpillar is used, the operator must be sure that the procedures are safe. The operator
must also be sure that the product will not be damaged or made unsafe by any unspecified
procedures.
The information, specifications, and illustrations in this publication are based on information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete and most current
information before you start any job.
When replacement parts are required for this product, Caterpillar recommends using Cat
replacement parts or parts with equivalent specifications including, but not limited to
physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information
and should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from
your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your
service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer
Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before operating or
performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This section provides
useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced
operator.
Photographs and illustrations guide the operator through correct procedures for using the tool
group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the
operator gains knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
Personal Protection/Important Information
Hazard Avoidance
Crushing Hazard (foot)

Crushing Hazard (hand)
Pinch Point
Working Load Limit (WLL) mark -

Do not use lifting device unless load
identification (WLL) markings are
legible.
Safety Alert - Do not use C-Frame

lifting device for anything other than
the intended purpose.
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools
Hotline at:
USA: 1-800-542-8665, Option 1
International: 1-309-578-7372
General Information Section

Introduction
The 223-2454 Tool Group is used to check and perform all on-engine fuel system adjustments,
including injector synchronization, timing and fuel setting (rack) on Cat 3114, 3116 and 3126
Engines equipped with mechanical unit injectors (MUI). The group also includes tools to remove
and install the unit injectors and adjust the valves.
The new group replaces the 1U-6680, 9U-7305, 128-8822 Tool Groups. . The new tools are
available individually to update former groups at a considerable cost savings, and offers the
advantage of simplified tooling which provides more accurate adjustments in less time.
Features of 223-2454 Tool Group
Injector Synchronization
The new 128-9640 Injector Synchronizing Fixture Group replaces the former 9U-7276 Linkage

Spring-Loading Tool and 9U-7275 Support. The new fixture features a spring-loaded plunger
which pushes directly on the end of the number 1 injector rack head. It is used with the 9U-
7270 Synchronizing Gauge Block (3.5 mm) or 220-0123 Synchronizing Gauge Block (3.0 mm) ,
which can be attached directly to the fixture.
The 128-8823 Long Nose Locking Pliers are used to clamp directly to the control rod (in
between two rocker stands), and is used as a lever to actuate the control rod in the fuel-on and
fuel-off directions. This ability to actuate the rack in both directions is necessary for consistent
readings when using the new procedure. The pliers replace the former 9U-7264 Linkage Lever .
Timing
The 123-4940 Magnetic Timing Indicator Fixture , used with the direct-reading 1U-

8869 Programmable Digital Position Indicator and associated tooling, moves quickly from
injector to make checking or adjusting the timing quick and easy.
Note: The 123-4940 Magnetic Timing Indicator Fixture replaced the original 9U-7308 Magnetic

Base , in order to adapt to an engine change to large-diameter elephant's foot rocker connections.
Note: New high-quality, deep offset, box wrenches are also part of this group, making timing
adjustment easier.
Fuel Setting
The 128-8827 Fuel Setting Pin is an approved version of the 9U-7271 Pin . The 128-8827 Fuel

Setting Pin is made easier to use in the very tight space that is available. It works on all versions
of governors.
The 130-2711 Holding Tool is used to hold the fuel setting pin against the governor housing
face. It is a redesigned version of the older 1U-6681 Holding Tool (part of the 1U-6680 Tool
Group), with modifications to make it easier to insert and allow alternate handle locations.
The 130-2711 Holding Tool replaces the 9U-7265 Clamp Assembly (part of 9U-7305) which
would not adapt to the later "Type V" version governor.
Valve Adjustment
The new double-ended (intake/exhaust) 123-4941 Valve Setting Feeler Gauge has special, short,
offset 45 degree legs. This design greatly simplifies setting valves on newer engines with a larger
diameter elephant's foot, and works on any engine with 0.38 mm (.015 inch) intake and 0.64 mm
(.025 inch) exhaust valve lash.
New high-quality, deep offset box wrenches make valve adjustments easier.
Injector Installation
The 1U-8013 Hex Bit Driver (5 mm) is included to tighten the injector hold-down bolt which
helps to reduce combustion gas leaks.
Tooling Nomenclature
223-2454 Tool Group
Refer to Tooling Nomenclature for 223-2454 Tool Group chart for item identification.

The tools shown in this chart are required to complete the synchronization and adjusting
procedures provided in this manual and in the machine's Service Manual.
Table 1
Nomenclature for 223-2454 Tool Group
Tools Required to
Upgrade Former
Groups
Item Part No. Description Qty. 9U-7305 1U-6680
Synchronization Tooling
Injector Synchronization Fixture
128-9640
1 Group 1 X X
128-8706
Spring Plunger (serviceable part)
9U-7270 Sync Gauge Block, 3.5 mm
2 1 X
220-8706 Sync Gauge Block, 3.0 mm
3 9U-5120 Solenoid Spanner Wrench 1
4 1U-8869 Digital Position Indicator 1
Locking Long Nose Pliers,
5 128-8823 1 X X
150 mm (6.0 inch) long
6 1U-6675 Spring Compressor 6
7 8T-4177 Bolt, Spring Compressor 6
9U-7282 Indicator Fixture Group
8 1
9U-6272 Nylon Screw (serviceable part)
9 8C-4984 Bolt, Indicator Stand 1
Contact Point (
10 9U-7263 1 X
18.5mm (.73 inch) long
Fuel Timing Tooling
11 9U-7269 Timing Gauge Block 1 X
12 123-4940
2
Magnetic Base Group 1 X
2
X
Deep Offset Wrench, 16 mm and
13 128-8824 1 R R
18 mm
Deep Offset Wrench, 17 mm and
14 128-8825 1 R R
19 mm
Contact Point,
15 9U-7274 1
85 mm (3.35) long
Miscellaneous Engine Tools
16 5P-0302
3
Injector Removal Bar 1
Valve Setting Gauge (feeler gauge
17 123-4941 3
1 X X
for adjusting valves)
18 194-3542 3
Hex Socket Bit Driver, 5 mm 1 R R
Fuel Setting Tooling
19 130-2711 Fuel Setting Holding Tool 1 R
20 136-4149 Governor Connection Pliers 1
21 128-8827 Fuel Setting Pin Assembly 1 R X
Pin Insert Pilot (use with 128-
22 1U-7523
3
1 X
8827 Pin Assembly)
Adjustment (FRC) Wrench (Type
23 1U-7299 1 X X
V, 1994 and later trucks)
T-Handle Wrench, 3mm hex (Type
24 1U-7300 1 X X
V, 1994 and later trucks)
Injector Sync and FRC Adjust
25 1U-6673 Wrench (all models, except Type 1
V and later trucks)
--- 6V-7145 Case 1
--- 128-8828 Foam Insert Group 1 R R
--- NEEG2688 Decal R R
--- NEHS0610 Tool Operating Manual 1 X X
(X) Essential tools for new products
(R) Recommended for improved tools
(2) Some of the former 9U-7305 Groups used the new 123-4940 Magnetic Base. Check your
specific tool group.
(3) Refer to the appropriate engine Service Manual for additional information on use of these
tools.
Tool Placement
The following illustration shows the placement of tools in the foam insert.
Placement Of Tools in the 223-2454 Tool Group. Refer to Tooling Nomenclature for item
identification.
Note: One dial indicator is included in the 223-2454 Tool Group , which is all that is required to
perform the procedures described in this manual.
Operation Section
Injector Synchronization
Injector synchronization is the setting of all injector racks to a reference position so each injector
gives the same amount of fuel to each cylinder. This is done by setting each injector rack to the
same position while the control linkage is in a fixed position (called the synchronizing position).
Synchronizing injectors are accomplished in this procedure by placing the Sync Gauge Block
between the injector rack head pin and the injector body of number 1 injector.
Note: There is no adjustment screw in the control linkage lever for number 1 injector, since it is
the reference point for all the other injectors. Therefore, no synchronizing adjustment is made for
the number 1 injector.
Always synchronize an injector after it has been removed and reused/replaced. If the number 1
injector is reused or replaced, synchronization on ALL injectors must be checked and adjusted.
Tooling and Equipment
The tools shown in Chart A "Injector Synchronization Tooling" are required to complete the
synchronizing procedure.
Table 2
Chart A.
Injector Synchronization Tooling
Part No. Description Qty. Item?
128-9640 Injector Synchronization Fixture Group 1 1
9U-7270 Sync Gauge Block 1 2
220-0123 Sync Gauge Block 1 2
9U-5120 Spanner Wrench (solenoid) 1 3
1U-8869 Position Indicator (digital) 1 4
Locking Long Nose Pliers
128-8823 1 5
150 mm (6.0 inch) long
1U-6675 Spring Compressor 6 6
8T-4177 Bolt, Spring Compressor 6 7
9U-7282 Indicator Fixture Group 1 8
8C-4984 Bolt, Indicator Stand 1 9
Contact Point
9U-7263 1 10
18.5 mm (.728 inch)
1U-6673 Adjustment Wrench 1 25
(?) Refer to nomenclature chart at the beginning of this manual for item identification.
Optional Removal of Rocker Arm Assembly
While synchronizing the injectors, removal of rocker arm assemblies will provide greater access
and visibility of control linkage and injector rack. This procedure includes steps for removing
rocker arm assemblies for both the number 1 injector and the injector being checked. However,
removal of rocker arm assemblies is optional for the injector being checked. If the person
performing the work is very familiar with the procedures and hardware involved, it is possible to
check and adjust injector synchronization with the rocker mechanism in place.
NOTICE
Since visibility of control linkage and injector is very limited with
rocker arm assembly in place, care must be taken to make sure that the
tooling is located properly and the procedure is completed correctly.
A complete set of 1U-6675 Spring Compressors is supplied in the 223-2454 Tool Group . This is

useful when rebuilding an engine (or when a control linkage has been replaced) to allow all the
injectors to be synchronized without the rocker arms in the way.
NOTICE
The injector spring must be slightly compressed to allow free movement
of the injector rack. Either the rocker arm assembly or the 1U-
6675 Spring Compressor (6) MUST be installed on all injectors to
prevent internal damage to the injectors.
Note: If rocker arm assemblies are removed, checking valve clearance and fuel timing is
recommended.
Synchronizing Procedure
Fuel Shut-Off Solenoid (energize to run). (1) Governor
(2) Fuel Shut-Off Solenoid
(3) 9U-5120 Spanner Wrench
1. Stop the engine and turn OFF electrical system.

2. Remove fuel shut-off solenoid (2) using a 9U-5120 Spanner Wrench (3). Removing the
solenoid allows free movement of injector rack control linkage during injector
synchronization.
3. Remove the cylinder head valve cover.
Remove number 1 Rocker Arm Assembly
(4) Bolts
(5) Rocker Arm Assembly
4. Remove four bolts (4) and number 1 cylinder rocker arm assembly (5). Remove the push
rods (intake, exhaust, and injector), making sure to mark their location. The push rods
should be reinstalled in their original locations to minimize readjustment of the valves.
Note: To prevent accidental disassembly, hold rocker arm assembly (5) level when
removing from the engine
Install Spring Compressor on number 1 Injector.
(6) 1U-6675 Spring Compressor
(7) 8T-4177 Bolt
5. Apply a small amount of clean engine oil to the top of the injector and install 1U-
6675 Spring Compressor (6) and 8T-4177 Bolt (7) into the rocker arm bolt hole.
NOTICE
of the injector rack. Either the rocker arm assembly or the 1U-
6675 Spring Compressor (6) MUST be installed on all injectors to
prevent internal damage to the injectors.
Install 128-9640 Injector Synchronization Fixture Group (8)
6. Install 128-9640 Injector Synchronization Fixture Group (8) by threading the two pins of

the fixture group into the rocker arm bolt holes. Tighten the threaded pins finger tight.
NOTICE
To prevent engine damage, the 9U-7270 or 220-0123 Sync Gauge should
always be attached to the 128-9640 Injector Synchronization Fixture
Group with the chain. This will prevent the gauge from being left inside
the engine.
Attach Locking Pliers (9) to Control Rod.
(B) Fuel-Off Direction
(C) Fuel-On Direction
7. Attach 128-8823 Locking Pliers (9) firmly to the control rod, as shown. The pliers should
be attached at an approximate 45 degree angle.
Note: Slight marring (damage) of the control rod by the locking pliers is acceptable. Do
not clamp the locking pliers right next to one of the control shaft bearing supports.
Note: Make sure that there is no interference between the pliers and the sides of the
rocker arm assemblies. Also, make sure that the ends of the locking pliers do not contact
the cylinder head bolt under the control rod. The locking pliers and control rod must
actuate freely and smoothly throughout the rack travel range.
8. Make sure injector rack stop pin (11), the square shoulder on the injector body (10), and
rack head (12) are clean.
Clean The Area Around The Injector Rack
(10) Square Shoulder On Injector Body
(11) Injector Rack Head Stop Pin
(12) Rack Head
9. Install proper Sync Gauge Block (13) .

a. Locate injector part number (see illustration for part number location).
a. Determine proper Sync Gauge Block using part number and Chart B.
a. Push locking pliers (9) and rotate the control rod to the "fuel-on" direction (so the
rack head pulls away from the injector).
a. Place the gauge block with the 3.0mm/3.5 mm wide "finger" between injector
rack head stop pin (11) and the square shoulder on injector body (10) .
a. Release the control rod (rotate to "fuel off"), allowing gauge block (13) to be held
tightly and squarely against the injector body.
Table 3
Chart B
Sync Gauge Block/Injector Cross Reference
Injector Part No Sync Gauge Block Used
127-8207
127-8213
140-8413
4P-2995
127-8228
127-8225
127-8216
173-4647
127-8220
127-8218
127-8222
162-0212
162-0218
220-0123 (3.0 mm)
127-8234
127-8209
127-8205
127-8211
127-8226
(13) Install Sync Gauge Block
(8) 128-9640 Injector Synchronization Fixture Group

10. If desired, remove the rocker arm assembly for the injector to be checked. This step is
optional. If the rocker arm assembly is not removed, proceed to Step 11.
a. Apply a small amount of clean engine oil to the top of the injector and install 1U-
6675 Spring Compressor (6) .
a. Tighten bolt (7) and compress the injector spring.
(15) Remove Bolt and Install Indicator Group
Injector Synchronization Tooling
(16) 9U-7282 Indicator Fixture Group
(17) 8C-4984 Bolt
(18) 9U-7263 Contact Point
(19) 1U-8869 Digital Position Indicator (Top-New Version, Botton-Former Version)
(20) 9U-6272 Nylon Screw (Part of 9U-7282)
(21) Lever (Part of 9U-7282)
11. Remove bolt (15) nearest the injector to be checked.
Injector Synchronization Tooling Installed
(17) 8C-4984 Bolt
(19) 1U-8869 Digital Position Indicator

Injector To Be Checked
(10) Square Shoulder On Injector Body
(12) Rack Head
(21) Lever
(22) Rack Bar
12. Install 9U-7263 Contact Point (18) 18.5 mm (0.73) long into 1U-8869 Digital Position

Indicator (19). Center the indicator in 9U-7282 Indicator Fixture Group (16) and
tighten 9U-6272 Nylon Screw (20) .
Note: The entire face of the 1U-8869 Digital Position Indicator can be rotated for better
visibility.
13. Make sure the end face of rack bar (22) on injector to be checked is clean. Install
assembled 9U-7282 Indicator Fixture Group (16) and 1U-8869 Digital Position Indicator
(19) with 8C-4984 Bolt (17) (M8 x 1.25 x 150 mm long) where bolt (15) was removed in
Step 11. Lever (21), on indicator fixture group, must contact and be centered on the end
face of rack bar (22). Tighten bolt (17) .
14. Turn indicator (19) to ON and make sure that the indicator units are set to mm, and ±
travel direction is correct (the plunger traveling out of the indicator should read positive).
Note: Make sure that the indicator is able to travel in both directions before proceeding to
the next step. If necessary, reposition the indicator in the indicator fixture group.
15. Using locking pliers (9), rotate control rod in the "fuel-off" direction until injector rack
head stop pin contacts the shoulder on the injector body.
NOTICE
The contact between the injector rack head stop pin and the shoulder
on the injector body is a solid stop. DO NOT put excessive force on it
once contact is made. Excessive force will cause damage to the control
assembly.
16. While maintaining the position of the control rod, with indicator (19) ON, press the
"zero-set" button. This defines the zero rack ("fuel-off") position.
17. Allow the linkage to spring back. Again rotate the control rod link to the "fuel-off"
position and check the zero position of the indicator.
Note: Repeat this step two or three times to confirm the reading. If the readings are not
consistent, check for binding.
18. Repeat this sequence several times, by pressing the zero set button as necessary, until it is
certain that a consistent zero reading is being obtained.
Injector Assembly Control Linkage
(24) Clamp Assembly
(25) Injector Lever

19. Using locking pliers (9), rotate the control rod in the "fuel-on" direction. Now, release
locking pliers (9). This makes sure the springs and bearings of the control linkage are in
their "normal" positions.
Note: Using the method described in Step 20 lets the spring plunger push the linkage
against the gauge block, providing the most consistent results.
20. Rotate the control rod in the "fuel-off" direction with the locking pliers and then release.
Indicator (19) should now read 3.50 ± 0.02 mm, if using the 9U-7270 Sync Gauge , or 3.0
± 0.02, if using the 220-0123 Sync Gauge.
Note: Repeat this step two or three times to confirm the reading. If the readings are not
consistent, check for binding.
21. If the indicator reading is within the specified tolerance, go to STEP 25.
22. If the indicator reading is not within the specified tolerance, go to the next step.
Synchronizing Injector (Side View)
(10) Square Shoulder on Injector Body
(21) Lever
(22) Rack Bar
(25) U-Shaped Lever
(26) Setscrew
(28) Clamp
NOTICE
DO NOT loosen screws holding clamps (28) to control shaft. Loosening
the clamps will cause poor engine performance and may damage the
engine.(The screws can be identified as those with socket heads filled
with sealant.) Clamps (28) are factory preset onto the shaft.
23. Use 1U-6673 Wrench (14) to loosen lock nut and turn setscrew (26) clockwise until
indicator (19) reads 3.50 ± 0.02 mm, if using the 9U-7270 Sync Gauge , or 3.0 ± 0.02, if
using the 220-0123 Sync Gauge . Turning the adjusting screw clockwise increases
reading; counterclockwise decreases reading. Tighten the locknut while holding setscrew
(26) in position.
24. Check the adjustment by rotating the control rod, in the "fuel-off" direction, with the
locking pliers and then release. If the indicator does not read 3.50 ± 0.02 mm, if using
the 9U-7270 Sync Gauge , or 3.0 ± 0.02, if using the 220-0123 Sync Gauge , re-adjust
setscrew (26) again.
25. After the injector is synchronized, remove indicator fixture group (16) and indicator (19).
Install bolt (15) and tighten to 25 ± 25 Nm (18.5 ± 5 lb ft).
26. If the rocker arm assembly was removed for the injector that was checked, remove spring
compressor (6). Install the rocker arm assembly (follow standard torque specifications).
Make sure that the push rods are properly seated in the rocker arms and lifters.
27. Synchronize the remaining injectors as necessary.
28. When synchronization procedure is complete, remove synchronization fixture (8) and
sync gauge block (13) from the number 1 injector. Remove locking pliers (9) .
29. If fuel setting is to be checked, refer to the "Fuel Setting" section in this manual.
30. If the fuel setting is known to be correct, remove spring compressor (6) from number 1
injector. Install the rocker arm assembly and tighten the bolts to 25 ± 7 Nm (18.5 ± 5 lb
ft). Make sure that the push rods are properly seated in the rocker arms and lifters are in
their original positions.
31. Check valve clearance and fuel timing for cylinders that had rocker arms removed. Refer
to the "Fuel Timing" section in this manual, and "Valve Clearance" in the Engine Service
Manual.
32. With the engine stopped and the engine electrical system shut OFF, install the fuel shut-
off solenoid. Install the valve cover
Fuel Setting
The tools shown in Chart C "Fuel Setting Tooling" are required to complete the fuel setting
procedure.
Table 4
Chart C
Part No Description Qty Item (1)
9U-5120 Spanner (solenoid) Wrench 1 3

1U-8869 Digital Position Indicator 1 4
9U-7282 Indicator Fixture Group 1 8
9U-6272 Nylon Screw 1 ---
130-2711 Holding Tool 1 19
136-4149 Governor Connection Pliers 1 20
1U-7299 Adjustment Wrench 1 23
1U-7300 T-Handle 1 24
1U-6673 Wrench 1 25
128-8827 Fuel Setting Pin Assembly 1 21
( 1 )
Refer to nomenclature chart, at the beginning of this manual for item identification.
Fuel Setting Check
Fuel setting is the adjustment of the fuel setting screw to provide a specified injector rack
position measured on number 1 injector rack bar. The fuel setting screw limits the power output
of the engine by setting the maximum travel of all injector racks.
Before the fuel setting is checked, injectors must be correctly synchronized. Refer to "Injector
Synchronization" in this manual.
Note: This procedure is illustrated with the number 1 cylinder rocker arm assembly
installed. Greater access to the injector rack and control linkage is provided when the
number 1 rocker arm assembly is removed. Instructions for removing the rocker arm
assembly are given in the "Injector Synchronization" section. Checking valve clearance and fuel
timing is recommended after the rocker arm assembly is reinstalled.
NOTICE
of the injector rack. Either the rocker arm assembly, or the 1U-
6675 Spring Compressor , MUST be installed on all injectors to prevent
internal damage to the injectors.
1. With engine stopped and the engine electrical system shut off, remove the fuel control
solenoid to allow free movement of injector rack control linkage during fuel setting.
(15) Remove Bolt
2. Remove bolt (15) from the inlet manifold.

(17) 8C-4984 Bolt
(19) 1U-8869 Digital Position Indicator (Former and Current Style)
(20) 9U-6272 Nylon Screw (Part of 9U-7282)
(21) Lever (Part of 9U-7282
3. Install 1U-8869 Digital Position Indicator (19) in 9U-7282 Indicator Fixture Group (16).

Tighten nylon setscrew (20) .
Fuel Setting Indicator (Former Style) Installed
4. Make sure the end of rack bar (22) is clean. Install assembled 9U-7282 Indicator Fixture
Group (16) and indicator (19). Bolt of indicator group (17) is threaded into hole where
bolt (15) was removed from the engine valve base. Position the indicator group so that
the indicator stem is parallel to the rack bar of the number 1 injector group so that the
indicator stem is parallel to the rack bar of the number 1 injector (perpendicular to the
rocker arm shafts). Lever (21) must contact the end face of rack bar (22) .
Number 1 Injector
(10) Square Shoulder On Injector
(12) Rack Head
(21) Lever
(22) Rack Bar
5. Remove clip (39) that keeps sleeve (40) in position between governor (1) and cylinder
head (41) .
(1) Governor
(39) Clip
(40) Sleeve
(41) Cylinder Head

Note: Do not use hard-jaw pliers to move sleeve (40). Damage of the sleeve will result in
damage to the wiper seal in cylinder head (41). This damage will occur when sleeve (40)
is retracted to allow access to governor link connection pin (42) .
6. With 136-4149 Governor Connection Pliers , slide sleeve (40) away from governor (1)
into cylinder head (41) .
7. Install 128-8827 Fuel Setting Pin Assembly (43) into link pin (42) of the governor output
shaft. When properly installed, equal lengths of small diameter on pin (43) will extend
from both ends of link pin (42) .
Governor Viewed From Rear Side
(1) Governor
(40) Sleeve
(41) Cylinder Head
(42) Link Pin
(43) 128-8827 Fuel Setting Pin Assembly
(44) 130-2711 Holding Tool
(47) Face of Governor

Note: 1U-7523 Pin Insert Pilot is included in this tool group. It is used with the 128-
8827 Fuel Setting Pin Assembly to align the links and insert pin (42). The 1U-7523 is
only used if the governor has been disconnected.
Note: For "Type V" version governors, the 128-8827 Fuel Setting Pin Assembly (43)
must be inserted from the front of the link pin, as shown. For all other governors, the pin
can be inserted from the rear of the governor.
8. Install 130-2711 Holding Tool (44) to hold fuel setting pin assembly (43) tightly against
governor housing calibration face (47) .
Note: If the holding tool is installed too tightly, the governor can be deflected away from
the engine, making the fuel setting adjustments incorrect.
Note: If the small diameter of calibration pin (43) does not contact governor calibration
face (47), remove air line connected to the governor fuel ratio control (FRC). Use FT-
1906 Fabricated Tester (or other REGULATED air supply) and apply 105 kPa (15 psi)
air pressure to the FRC. Pressurizing the FRC will prevent it from restricting the
movement of the governor output, thus allowing the calibration pin to contact governor
calibration face (47). After the fuel setting check is completed, remove the FT-
1906 Fabricated Tester and install the air line to the FRC.
9. Turn indicator (19) to ON. Make sure that the indicator units are set to mm and ± travel
direction is correct (plunger traveling out of indicator should read positive).
10. Firmly push rack head (12) of number 1 injector, by hand, toward the injector until rack
head stop pin (11) touches square shoulder of injector body (10), and hold in this
position. The number 1 injector is now at "fuel-off". Press the "zero-set" button on the
indicator to define zero rack at this position.
Note: If rocker arm assembly is installed, rotate the control shaft in the "fuel-off"
direction (against spring pressure). Rotate the shaft until ALL injector levers are in the
shut-off position before pressing the "zero-set" button. This makes sure that number 1
injector rack is at zero.
Note: The 128-8823 Locking Long Nose Pliers may be used to actuate the control

linkage throughout this procedure. (Refer to the description in the "Injector
Synchronization" section for additional information.)
11. Release number 1 rack head (or control rod, if rocker arms were not removed), then push
it back into zero rack. Repeat several times to make sure that a consistent zero point has
been established.
12. Push down on rack lever (46) and quickly release it. Flip the lever in this manner several
times to make sure that there is smooth movement on the injector rack.
13. Refer to the "Engine Information Plate" or the "Fuel Setting and Related Information"
area of TMI for the correct fuel setting.
14. If reading on digital indicator is within ± 0.25 mm of the specified fuel setting, go to Step
17.
15. If the fuel setting needs adjustment, use 1U-6673 Wrench or 1U-7299/1U-

7300 Adjustment Wrench to loosen the locknut of fuel setting screw (45). Adjust fuel
setting screw (45) until the indicator reading matches the correct fuel setting. Turn screw
(45) CCW for more fuel (greater fuel setting) or CW for less fuel (lower fuel setting).
NOTICE
Do not loosen screw holding clamp assembly (15) to the control rod.
This screw can be identified by sealant in socket head. Clamp assembly
(15) is factory preset onto the rod. Loosening the clamp will cause poor
performance and may damage the engine.
16. With the 1U-6673 or 1U-7299/1U-7300 Wrench, hold fuel setting screw (45) in position

and tighten the locknut. Recheck the fuel setting by flipping (pushing down and
releasing) lever (46). Check the reading on the indicator again. If the fuel setting is not
correct, repeat Steps 15 and 16 until the correct settings are obtained.
17. Remove holding tool (44) and fuel setting pin assembly (43) from the engine. Use 136-
4149 Governor Connection Pliers to slide sleeve (40) back into the governor (lubricate
the O-ring seal on the sleeve with engine oil, if needed). Install clip (39) .
18. Remove indicator fixture group (16) and indicator (19). Install bolt (15) into engine valve
base and tighten to 25 ± 7Nm (18.5 ± 5 lb ft.
Note: If the rocker arm assembly was removed for this procedure, remove 1U-
6675 Spring Compressor. Install rocker arm assembly. Make sure that push rods are
properly seated in the rocker arms and lifters. Check valve clearance and fuel timing.
Refer to "Valve Clearance" and "Fuel Timing" sections in the engine service manual.
19. With engine stopped and the engine electrical system turned OFF, install the fuel shut-off
solenoid. Install the valve cover.
Fuel Timing
The tools shown in Chart D, "Fuel Timing Tooling" are required to complete the fuel timing
procedure.
Table 5
Chart D.Fuel Timing Tooling
1U-8869 Digital Position Indicator 1 4

9U-7269 Timing Gauge Block 1 11
123-4940 Magnetic Base Group 1 12
9U-6272 Nylon Holding Screw 1 -----
128-8824 Wrench, 16 mm and 18 mm 1 13
128-8825 Wrench, 17 mm and 19 mm 1 14
9U-7274 Contact Point, 85 mm (3.35 in) long 1 15
( 1 )
Refer to the nomenclature chart, at the beginning of this manual, for item identification.
Indicator Calibration
Before a check or an adjustment of the fuel timing dimension can be made, the 1U-8859 Digital
Position Indicator (19) must be calibrated. Refer to the following calibration procedure. There is
a procedure for both the former indicator group and the current indicator group.
Initial Calibration Setup

Calibrate Injector Timing Tooling
(20) 9U-6272 Nylon Holding Screw (Part of 9U-7282)
(29) 123-4940 Indicator Fixture Group
(30) 9U-7269 Timing Gauge Block
1. Install 85mm (3.35 inch) long 9U-7274 Contact Point (31) on the digital position
indicator stem.
2. Insert digital position indicator (19) in 123-4940 Magnetic Base Group (29) until it stops.
Tighten nylon holding screw (20) .
3. Make SURE the magnetic bottom of indicator fixture group (29) is clean (NO particles
sticking to magnet). Also make sure both the top and the shoulder of 9U-7269 Timing
Gauge Block are clean.
4. Push (fully retract) indicator contact point (31) into the digital position indicator and hold
it.
NOTICE
The magnets in the 123-4940 Indicator Fixture Group (29) are very
powerful and can snap into place when attaching the base assembly to
any metallic surface. To avoid damaging the digital position indicator,
hold the indicator contact point in the retracted position while
attaching the base.
5. Carefully place the indicator and base assembly on timing gauge block (30). Once the
base firmly attaches to the gauge block, release (extend) contact point (31) .
Indicator Group (Current Style)
6. Preset (calibrate) the indicator group. Refer to the appropriate procedure based on the
digital indicator group (former style or current style) in use.
Note: Check the travel of the dial indicator. As the contact point is pressed in towards the
dial, the reading on the indicator should decrease.
Presetting the Indicator Group (Former Style)
Program 1U-8869 Digital Position Indicator (19) to a preset value of 62 mm (2.4 inch) (the

dimension of 9U-7269 Timing Gauge Block ), as follows:
Indicator Group (Former Style)
1. Turn the indicator ON by pressing the ON/OFF button (4) .
2. Press the in/mm button (2) to change the display to millimeters.
3. Indicator bar (6) should be in the display window under REV. If the space is blank, select
+/- button (1) so the display shows the indicator bar, as shown.
4. Press and hold the preset button (3) until there is a flashing (P) on the upper right corner
of the display. When the flashing (P) appears, release the button.
1U-8869 Digital Position Indicator (Former Style)
(1) Positive/Negative Select Button
(2) Inch/Millimeter Select Button
(3) Preset Button
(4) On/Off Button
(5) Zero/ABS Button
(6) Indicator Bar

Note: Press and hold the preset button to change the positions of the flashing cursor.
Also, press and release the preset button to change the value of the number.
5. Press and hold the preset button (3) until the (P) stops flashing, and a flashing indicator
bar is seen in the lower left corner of the display. When the indicator bar appears, release
the button. Pressing and releasing the preset button will cause a minus sign to appear or
disappear above the flashing indicator. Use the preset button to make this position blank.
6. Press and hold the preset button (3) until the flashing indicator begins to flash under the
first number position (fourth position to the left of the decimal), then release the button.
Pressing and releasing the preset button will cause the display number in that position to
change.
7. Use the preset button to move the flashing indicator and change the value of the display
numbers to read 0062.00 mm (2.4 inch).
8. Press and hold the preset button until the flashing (P) shows in the upper right corner of
the display, and then release the button. Momentarily push the preset button so the
flashing (P) and the zeros to the left of 62.0 mm (2.4 inch) disappear.
Note: To recall a preset number, repeat Steps 1 through 4, then press and release the
preset button so the flashing (P) and the zeroes to the left of 62.0 mm (2.4 inch)
disappear.
9. Turn the indicator OFF. The indicator will retain the preset number in memory (only one
preset number is retained).
Presetting the Indicator Group (Current Style)
Program 1U-8869 Digital Position Indicator (19) to a preset value of 62.0 mm (2.4 inch) (the
dimension of 9U-7269 Timing Gauge Block ), as follows:
Indicator Group (Current Style)
(20) 9U-6272 Nylon Holding Screw (Part of 9U-7282
1U-8869 Digital Position Indicator (Current Style)
(1) Inch/Millimeter Select Button
(2) Positive/Negative Select Button
(3) Zero/ABS Button
(4) Preset Button
(5) Tolerance Button
(6) On/Off Button
1. Turn the indicator ON by pressing the ON/OFF button (6) .
2. Press in/mm button (1) to change the display to millimeters.
3. Press and hold the preset button (4) until the (+ or -) sign flashes. If the indicator displays
(-), reset to (+).
Note: Press preset once to go into programming mode. Press and hold to advance
position. Press and release to increase number.
4. Press and hold the preset button until the first character begins to flash. Release the
button when character flashes.
5. Press and release the preset button to set the value of the character.
6. Repeat Steps 4 and 5 until the display numbers read 0062.00 mm (2.4 inch).
Correctly Entered Display Numbers
7. Press and hold the preset button until (P) starts flashing.
8. Press and release the preset button. The indicator is now preset and should read +0062.00
mm (2.4 inch).
Measuring Fuel Timing Setting
Table 6
Chart E-1
3114 Crankshaft Positions For Fuel Timing Setting and Valve Lash Setting
SAE Standard (Counterclockwise) Rotation Engines As Viewed From The Flywheel End
Item Cylinders to Adjust
Check/adjust with Number 1 piston on TC compression stroke?
Injectors 3-4
Inlet Valves 1-2
Exhaust Valves 1-3

Check/adjust with Number 1 piston on TC exhaust stroke
2
Injectors 1-2
Inlet Valves 3-4
Exhaust Valves 2-4
Firing Order 1-3-4-2
1. Note: The number 1 injector is not checked or adjusted with the number 1 piston on Top
Center (TC) compression stroke. Be certain that the number 1 piston is TC on the correct
stroke (compression or exhaust) to check or adjust each cylinder (injector). Refer to the
topic "Finding Top Center for number 1 Piston" in this manual.
2. Note: After TC position for a particular stroke is found and the cylinders are checked or
adjusted, remove timing bolt and turn the flywheel counterclockwise 360 degrees. This
will put number 1 piston at TC on the exhaust stroke. Install timing bolt in the flywheel
and check or adjust the remaining cylinders (injectors).
Note: Refer to Testing and Adjusting Engine Valve Lash - Inspect/Adjust, for more information
on adjusting valves.
Table 7
Chart E-2
3116, 3126 Crankshaft Positions For Fuel Timing Setting and Valve Lash Setting
SAE Standard (Counterclockwise) Rotation Engines As Viewed From The Flywheel End
Item Cylinders to Adjust
Check/adjust with Number 1 piston on TC compression stroke?

Injectors 3-5-6
Inlet Valves 1-2-4
Exhaust Valves 1-3-5
Check/adjust with Number 1 piston on TC exhaust stroke
2
Injectors 1-2-4
Inlet Valves 3-5-6
Exhaust Valves 2-4-6
Firing Order 1-5-3-6-2-4
1. Note: The number 1 injector is not checked or adjusted with the number 1 piston on Top
Center (TC) compression stroke. Be certain that the number 1 piston is TC on the correct
stroke (compression or exhaust) to check or adjust each cylinder (injector). Refer to the
topic "Finding Top Center for number 1 Piston" in this manual.
2. Note: After TC position for a particular stroke is found, and the cylinders are checked or
adjusted, remove timing bolt and turn the flywheel counterclockwise 360 degrees. This
will put number 1 piston at TC on the exhaust stroke. Install timing bolt in the flywheel
and check or adjust the remaining cylinders (injectors).
3116, 3126 Cylinder and Valve Location
Note: Refer to Testing and Adjusting, Engine Valve Lash - Inspect/Adjust for more information
on adjusting valves.
With the crankshaft positions given in Charts E, Crankshaft Positions for Fuel Timing Setting, all
of the injectors can be checked or adjusted. This will make sure that push rod lifters are off the
lobes and on base circles of the camshaft.
Note: Always rotate the engine crankshaft with four large bolts on the front of the crankshaft. Do
not use eight small bolts on the front of the crankshaft pulley.
Note: If the rocker arm assemblies are removed and installed prior to checking the fuel timing
dimension, rotate the crankshaft two complete revolutions to allow rocker arms to properly seat
on injectors before checking the timing dimension.
1. Put number 1 piston at top center (TC) position and determine the stroke (compression or
exhaust). Refer to Finding Top Center Position for Number 1 Piston, in the engine service
manual.
2. Make sure the top surfaces of the injector tappet (32) and shoulder (34) are clean and dry.
Fuel Timing Dimensions
(32) Injector Tappet
(33) Adjustment Screw
(34) Shoulder
(A) Fuel Timing Dimension
3. Remove indicator and magnetic base from the gauge block. Push (fully retract) indicator
contact point (31) into the digital position indicator.
4. Hold the contact point in the retracted position and carefully position it on top of injector
tappet (32) for the injector to be checked.
NOTICE
The magnets in the 123-4940 Indicator Fixture Group (29) are very
powerful and can snap into place when attaching the base assembly to
any metallic surface. To avoid damaging the digital position indicator,
hold the indicator contact point in the retracted position while
attaching the base.
Timing Fixture Installed (Current Style)
Timing Fixture (Former Style)
(33) Adjustment Screw

Note: The shoulder of the injector is not very wide. It is easy to set the contact point on
the cylinder head and not the shoulder of the injector. Make sure that the contact point is
sitting on the injector shoulder (34) .
5. Release (extend) the indicator plunger and carefully position indicator contact point (31)
on the shoulder of the injector (34). Make sure that it moves freely and the contact point
does not bind on the injector spring.
(32) Injector Tappet
(34) Shoulder
NOTICE
After the timing tooling has been positioned on an injector, do not
rotate the engine. The timing tooling could be damaged.
6. Indicator (19) will display the fuel timing dimension directly.
Note: Refer to the engine information plate or the Fuel Setting and Related Information
section in TMI for the correct fuel timing dimension. The indicator must show the correct
fuel timing dimension within ± 0.20 mm (0.008 inch). Each injector must be checked
separately and adjusted, if necessary.
7. If indicator (19) displays the correct dimension, or is within the ±0.20 mm (0.008 inch)
checking tolerance, no adjustment is necessary. Proceed to Step 14.
8. If indicator (19) does not show the correct timing dimension, use the 128-8824 or
the 128-8825 Wrench to loosen the locknut on the push rod adjustment screw (33) for the
injector to be adjusted.
9. Turn adjustment screw (33) until indicator (19) displays the correct fuel timing
dimension. Tighten locknut to 25 ±7 Nm (18.0 ± 5.0 lb ft) and check adjustment again. If
necessary, repeat this procedure until the adjustment is correct.
10. Sequence for checking the fuel timing dimensions. Refer to explanation at the beginning
of this section.
a. Check and adjust fuel timing dimension on half of cylinders with the timing bolt
installed.
a. Remove the timing bolt and timing tooling.
a. Rotate flywheel counterclockwise 360 degrees (1 revolution) and install timing

bolt.
a. Place timing tooling on remaining injectors and check the fuel timing dimension.
Refer to Chart E, Crankshaft Positions for Fuel Timing Setting.
Note: Half of the cylinders can be checked in each engine rotation. For more information,
refer to Chart E.
11. Remove timing bolt from flywheel when the fuel timing check is completed.
Finding Top Center Position for Number 1 Piston

The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to
complete the procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item
(1)
8T-4177 Bolt, Spring Compressor 1 7

( 1 )
Refer to the nomenclature chart at the beginning of this manual for item identification.
Procedure
Timing Bolt Location
(35) 8T-4177 Timing Bolt
(36) Timing Hole
(37) Flywheel Housing

Note: Depending on engine application, timing hole (36) is located at either the left front
face or the right front face of the flywheel housing.
1. Remove plug from the timing hole (36) on the front of the flywheel housing.
NOTICE
Rotate the engine with four large bolts on the front of the crankshaft.
Do not use the eight small bolts on the front of the crankshaft pulley as
this could cause damage to the engine.
2. Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the
timing bolt engages with the threaded hole in the flywheel.
Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded
hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the
flywheel counterclockwise until the timing bolt engages with the threaded hole. This
procedure makes sure that the play is removed from the gears when number 1 piston is
put on TC.
3. Remove the cylinder head valve cover.
Valve Cover Removed
4. The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1
piston is on the compression stroke and the rocker arms can be moved by hand. If the
rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on
the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to
determine which cylinders can be checked/adjusted (determined by stroke position of
crankshaft when timing bolt is installed).
Note: When the actual stroke position is identified, and the other stroke position is
desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel
counterclockwise 360 degrees, and reinstall the timing bolt.
5. After TC position for a particular stroke is obtained and adjustments are made, remove
the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number
1 piston at TC position on the other stroke. Install timing bolt in the flywheel and
complete adjustments for remaining cylinders.
Removal and Installation of Unit Fuel Injectors

Table 9
Chart G
Injector Removal and Installation Tools
5P-0302 Injector Removal Bar 1 16

194-3542 Hex Socket Bit Driver, 5 mm 1 18
( 1 )
Refer to nomenclature chart, at the beginning of this manual for item identification.
Unit Fuel Injector
(48) Bolt
(49) O-Rings
Note: Not all injectors use a bottom O-ring.
Removal
1. Remove injector hold down bolt (48) .
NOTICE
Do not pry on the injector hold down bracket. Damage to the injector
could occur. The injector has a notch on the side opposite the rack that
is used for prying the injector loose.
2. Use the 5P-0302 Injector Removal Bar to loosen the fuel injector.
3. Rotate the injector to disengage the injector rack from the control linkage.
4. Remove the injector and inspect it to be sure the O-rings (49) were removed with the
injector.
NOTICE
Do not move the fuel injector rack with the injector spring slightly
compressed. Damage to the injector could occur.
Installation
Note: Not all injectors use a bottom O-ring.
1. With O-rings in place and lubricated with engine oil, position the injector in the head and
then rotate it to engage the injector rack with the control linkage.
2. Push down on the top of the injector so that the O-ring seals slide into the bore of the
cylinder head. Be sure that the injector is fully seated in the bore before installing the
bolt.
Note: Do not use the bolt to pull the injector down into the cylinder head.
3. Install bolt (48) using the 194-3542 Hex Socket Bit Driver and tighten it to 12 ±3 Nm (9
± 2 lb ft).
4. Complete the installation by performing the injector synchronization procedure in this

manual.
5. Install the rocker assembly and adjust fuel timing and valve clearance. The fuel setting
should also be checked.
3114, 3116 and 3126 Engines Caterpillar
Unit Injector
Usage:
AP-1000 1HD
This procedure is an inspection of the unit injectors and the rocker arm assemblies.
1. Remove the valve cover.

2. Without removing any injectors, inspect the injectors for seizures and for cracked springs
or broken springs. A seized injector can be identified by a compressed spring and a loose
rocker arm. Replace seized injectors. Check for bent push rods or rocker arms. Replace
damaged parts with new parts, as needed. Replace injectors that have broken springs or
cracked springs. Ream the injector sleeve if the seat area for the injector is pitted.
Replace the injector sleeve, if necessary. Refer to Tool Operating Manual, NEHS0738,
"Using the Injector Seating Tool " and Tool Operating Manual, NEHS0610, "Using
the 128-8822 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit
Injectors (MUI)" for additional information about replacing injectors. Also, refer to
Video Tape, LEVN4032, "Troubleshooting Guide for the 3100 Family of Diesel
Engines" and Video Tape, LEVN4732, "Injector Seating Procedure". Verify
synchronization and timing after an injector is reinstalled or an injector is replaced.
(1) Follower
(2) Thrust plate

3. Check the rocker arms and the rocker arm bolts for cracks, wear, or damage. Tighten the
rocker arm bolts evenly to a torque of 33 ± 7 N·m (24 ± 5 lb ft).
4. Check the contact between the rocker arm and the injector. If follower (1) for the rocker
arm is missing, replace the follower. Ensure that thrust plate (2) is in position on top of
the injector. If the thrust plate is not found, check the valve compartment. If the thrust
plate is located and the thrust plate is undamaged, reinstall the thrust plate. Use a new O-
ring if the thrust plate is reinstalled. Replace the injector if the thrust plate is not found.
Also replace the injector if the thrust plate is found but the thrust plate is damaged.
(3) Fuel injection rack
(4) Cone
(5) O-ring
5. Move each fuel injection rack (3) in order to check for binding. If a fuel injection rack is
binding, use the following procedure to correct the problem.
a. Remove the rocker stand and remove the hold-down bolt for the unit injector.
Rotate the injector in the cylinder head. The fuel injection rack may now be
disconnected from the linkage.
NOTICE
Do not remove the fuel control linkage or the fuel injection racks
without having the spring compressors installed. Damage to the
injectors may occur.
a. Use a 1U-6675 Spring Compressor to compress the fuel injector spring.
a. Move the fuel injection rack. If the fuel injection rack is still binding, replace the
injector.
a. Verify synchronization and timing after an injector is reinstalled or an injector is

replaced. Refer to the System Operations, Testing And Adjusting module. If the
fuel injection rack is no longer binding, the injector may have been seated
incorrectly.
a. Ensure that the fuel injection rack is centered. Ensure that the ball for the fuel
control linkage is centered. Torque the bolt for the injector hold-down bracket to
12 ± 3 N·m (106 ± 27 lb in).
6. Ensure that all of the hold down bolts for the injectors are tightened to a torque of 12 ± 3
N·m (106 ± 27 lb in). If an incorrectly tightened bolt is found, remove the injector that is
held down by the bolt. Examine the sealing surface for the injector sleeve. Ream the
injector sleeve if the seat area for the injector is pitted. Replace the injector sleeve, if
necessary. Replace the injector only if injector cone (4) is damaged. A burned O-ring or a
missing O-ring on the end of the injector does not indicate a faulty seal. The O-ring does
not need to be replaced. Verify synchronization and timing after an injector is reinstalled
or an injector is replaced. Refer to the System Operations, Testing And Adjusting
module.
Caterpillar Information System:
3114, 3116 and 3126 MUI Engine Governors Governor (Type VI) - Assemble
3114, 3116 and 3126 Engines Valve Train Noise
C9 On-Highway Truck Engines Air Compressor - Remove and Install
3612 and 3616 Engines Piston Cooling Jets - Remove and Install
3114, 3116 and 3126 Engines Unit Injector Misfire
3126B Engines for Caterpillar Built Machines Inlet and Exhaust Valve Guides - Remove and
Install
3114, 3116 and 3126 Engines Soot in Inlet Manifold
3126B Engines for Caterpillar Built Machines Engine Oil Filter Base - Assemble
C9 <BR>Engine For Caterpillar Built Machines Fuel Priming Pump - Remove and Install
3126B Truck Engine Unit Injector - Install
3126B Engines for Caterpillar Built Machines Engine Oil Filter Base - Disassemble
3126B Engines for Caterpillar Built Machines Engine Oil Filter Base - Install
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SR4B Generators Service Tools
G3612 and G3616 Engines Cylinder Liner - Remove
G3612 and G3616 Engines Cylinder Liner - Install
SR4B Generators Coupling - Install
G3612 and G3616 Engines Camshaft - Remove
On-Highway Engines Electronic PTO Installation and Application Guide PTO Parameters -
Program
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SIS Information
 General Service Information

 Schematic
 Specifications
 Systems Operation
 Testing and Adjusting
 Troubleshooting
 Disassembly and Assembly
 Service Magazine
 Truck Engine News

 Engine News
 Lift Truck Technical Bulletin
 Operation and Maintenance Manual
Removal and Installation of Unit

Injectors on 3114, 3116, and 3126 MUI
Engines{1251, 1290} Caterpillar
Removal and Installation of Unit Injectors on 3114, 3116, and 3126 MUI Engines{1251, 1290}
Usage:
322B L 1AS
Engine: Truck with Mechanical Unit Injection 3114 3116

Engine:Commercial with Mechanical Unit Injection 3114 3116 3126
Engine:Machine with Mechanical Unit Injection 3114 3116 3126
Introduction
This Special Instruction contains the necessary procedure in order to install unit injectors for
3114, 3116, and 3126 MUI engines.
Removal and Installation Procedure

Note: To avoid damage to the unit injector during removal of the unit injector from the cylinder
head, refer to the Service Manual for the removal procedure of the unit injector.
Use the latest process for servicing the unit injector sleeves in the cylinder head before you
install replacement unit injectors. Refer to the Service Manual and other service news articles in
order to find the latest service information, including new tools and procedures.
Before a new unit injector or a remanufactured unit injector is installed into an engine, take
adequate precautions in order to clean the internal fuel lines and the unit injector sleeve. Also,
install a new Caterpillar high efficiency fuel filter.
Lubricate the injector rack bar with clean diesel fuel or 1U-8265 Penetrating Oil .
Incorrect testing procedure for the tappet spring
Do not depress the tappet spring. Refer to Illustration 1. Do not force the injector rack bar
in and out since this action may damage the internal parts of the unit injector. A tight rack
on a unit injector that is not installed in the engine is not an indication of a faulty unit injector.
Forcing the injector rack bar in and out may cause the unit injector to become damaged. Forcing
the injector rack bar in and out may possibly void all the warranty.
Do not test the unit injectors prior to engine installation. The unit injectors are tested 100% at
the factory and Pop Testing may contaminate the unit injector.
Before you install the unit injector, apply clean engine oil on the O-ring seals for ease of
installation.
Install the unit injector according to the procedure in the Service Manual by using 173-
1530 Injector Seating Tool . Tighten the unit injector clamp retaining bolt to a torque of 12 ± 3
N·m (9 ± 2 lb ft).
Verify the following parameters and settings according to the procedures in the Service Manual:
unit injector synchronization, fuel setting, fuel timing and valve lash. Adjust the parameters and
settings in order to meet specifications only.

Valve Lash Adjustment Guide

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Valve Lash Adjustment Guide

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Testing and Adjusting Ridho Bagus Fitriyanto | AB – 1K

Testing and Adjusting

Media Number -SENR9558-04 Publication Date -01/10/2008 Date Updated -29/10/2008

Engine Valve Lash - Inspect/Adjust

/ sisweb/ siswe b/ m / sisweb/ mediasea

Valve Lash Check

Valve Lash Adjustment

(A) Exhaust valves

(B) Inlet valves

(A) Exhaust valves

(B) Inlet valves

Use the following procedure to adjust the valve lash:

(2) Rocker arm

(3) Adjustment locknut

(4) Adjustment screw

3. Loosen adjustment locknut (3) .

9. Repeat Step 3 through Step 6 for these valve adjustments.

Refer to Testing and Adjusting, "Unit Injector - Adjust".

Using the 223-2454 Tool Group on 3114,

Unit Injectors (MUI){0374, 0599, 0701,

Engine: Commercial with Mechanical Unit Injection 3126

Important Safety Information

Improper operation, lubrication, maintenance, or repair of this product can be dangerous

The Safety Section lists basic safety precautions.

General Information Section

Personal Protection/Important Information

Crushing Hazard (foot)

Crushing Hazard (hand)

Working Load Limit (WLL) mark -

Safety Alert - Do not use C-Frame

Additional Contact Information

USA: 1-800-542-8665, Option 1

General Information Section

Features of 223-2454 Tool Group

The new 128-9640 Injector Synchronizing Fixture Group replaces the former 9U-7276 Linkage

The 123-4940 Magnetic Timing Indicator Fixture , used with the direct-reading 1U-

Note: The 123-4940 Magnetic Timing Indicator Fixture replaced the original 9U-7308 Magnetic

The 128-8827 Fuel Setting Pin is an approved version of the 9U-7271 Pin . The 128-8827 Fuel

Refer to Tooling Nomenclature for 223-2454 Tool Group chart for item identification.

(R) Recommended for improved tools

Tooling and Equipment

Optional Removal of Rocker Arm Assembly

A complete set of 1U-6675 Spring Compressors is supplied in the 223-2454 Tool Group . This is

(2) Fuel Shut-Off Solenoid

1. Stop the engine and turn OFF electrical system.

3. Remove the cylinder head valve cover.

(5) Rocker Arm Assembly

6. Install 128-9640 Injector Synchronization Fixture Group (8) by threading the two pins of

(B) Fuel-Off Direction

(C) Fuel-On Direction

(10) Square Shoulder On Injector Body

(11) Injector Rack Head Stop Pin

(12) Rack Head

9. Install proper Sync Gauge Block (13) .

(8) 128-9640 Injector Synchronization Fixture Group

a. Tighten bolt (7) and compress the injector spring.

(16) 9U-7282 Indicator Fixture Group

(19) 1U-8869 Digital Position Indicator (Top-New Version, Botton-Former Version)

(20) 9U-6272 Nylon Screw (Part of 9U-7282)

(21) Lever (Part of 9U-7282)

11. Remove bolt (15) nearest the injector to be checked.

(16) 9U-7282 Indicator Fixture Group

(19) 1U-8869 Digital Position Indicator